Stretchable Conductor Wire Embedding for Wearable Interconnects
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Solution Overview
Problem
Current technologies face challenges in creating low-cost, highly stretchable electrical and heat transfer arrangements that are robust and reliable, particularly for wearable applications where stretchability and cost-effectiveness are unmet needs.
Innovation Solution
A novel sew-and-transfer method using a sewing machine to embed conductor wires or heat conduits in a moldable medium, allowing for the creation of stretchable interconnects with up to 500% stretchability without altering electrical resistance or fluid mechanics, utilizing a dissolvable filament for temporary placement and a polymeric medium for adherence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fabrication processes are used for stretchable interconnects, then electrical connectivity can be achieved, but the devices exhibit limited stretchability, poor reliability, and large gauge factors
Solution Approach 1:
The conductor wire is arranged in a zigzag pattern rather than a straight line, segmenting the conductive path into multiple segments. This allows the conductor to stretch without breaking while maintaining electrical connectivity, resolving the contradiction between reliability and stretchability
Solution Approach 2:
The conductor wire is embedded within a moldable medium (elastomer) rather than being surface-mounted, adding a third dimension to the structure. This embedding provides mechanical support and protection, improving reliability while allowing the entire assembly to stretch uniformly
2Reliability
If conventional stretchable interconnects are designed, then some stretchability can be achieved, but the gauge factors are large and reliability remains poor
Solution Approach 1:
The invention uses a composite structure combining a conductor wire (metal) with a moldable medium (elastomer). This composite material approach allows the rigid conductor to maintain low gauge factor while the flexible elastomer provides stretchability and reliability, resolving the contradiction between reliability and manufacturing precision
3Adaptability or versatility
If wearable heat transfer arrangements are created, then heat transfer functionality can be achieved, but the arrangements lack sufficient stretchability and remain elusive to fabricate
Solution Approach 1:
The moldable medium serves multiple functions: it provides structural support, enables stretching, embeds the conductor wire, and can be molded into various shapes for different wearable applications. This multi-functionality achieves high adaptability while maintaining ease of manufacture through a single fabrication process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables the fabrication of highly stretchable and reliable electrical and heat transfer arrangements that maintain performance under high strain, suitable for wearable devices and medical applications, with stable resistance and minimal hysteresis, and can be integrated with other electronic components for versatile use.
Implementation Method 1
securing a dissolvable filament for temporary maintenance of placement of the conductor wire on the substrate
Implementation Method 2
the moldable medium having a thermal conductivity coefficient suitable for exchanging heating to or from a subject's body
Data Source
AI summary
A wearable accessory capable of communicating data to actuators or from sensors is disclosed. The wearable accessory includes a conductor wire disposed in a moldable medium according to a predetermined pattern, the moldable medium being an electrically insulating material, the conductor wire terminating at an input and an output.